Digital technology at Labelexpo

Labelexpo Asia 2005, taking place at the Shanghai New International Expo Center on 7-9 December 2005, is part of the Labelexpo Global Series, encompassing machinery shows in Europe and America, and conference-led events in India, Thailand, Japan, Mexico, and Brazil. At Labelexpo Europe 2005, which took place in September this year, a number of developments in the digital arena were announced and demonstrated – and at Labelexpo Asia in December many of the same companies will be exhibiting and showing their major new advances in digital label printing and solutions for the first time ever in Asia.

Digital developments at Labelexpo Europe 2005:

HP Indigo introduced the first fully digital label printing and converting system seen at a graphic arts exhibition. Called the Digital Laser Workflow, this system utilizes building blocks from multiple suppliers to create a system running from pre-press to variable imaging to laser die cutting and slitting using motorized knives. The pre-press end is based around an Esko-Graphics workstation that manages workflow onto the press, including Step Repeat and color management of the 7-color print engine. After printing on a ws4050 press, the line feeds into an ABG Omega Digicon converting line incorporating a Sabre Extreme laser label-cutting system and motorized slitting knives.

Once the Esko system has generated a Step Repeat file from the label design file, the die line is spooled to a server on the Digicon. The HPws4050 then prints a barcode onto the label referenced to that die-line profile. This is read by a reader on the Digicon, which downloads the appropriate information to the laser, allowing the cutting profile to be changed on the fly. The slitting section consists of two racks of up to 12 servo-controlled crush knives. One set of knives cuts while the second positions itself for the next job. A turret rewinder completes the line. 

On the HP Indigo demonstration three consecutive cutter changes and five text changes were shown carried out on the fly. This variant of the Omega Digicon line is expected to sell for around $350,000.

There was some discussion about a final step on the digital workflow path – a digital cold foil unit. This could involve digitally printing an image – perhaps by inkjet – then running in cold foil and curing.

A rejuvenated Xeikon, boosted by strong support from owner Punch Graphics, showed its LabelSprint digital press system with in-line D-Coat finishing line - and announced the sale of four machines to printers as far a field as Poland, Italy and Japan. The most comprehensively specified was sold to Italian label printer Indet. The solution included a Xeikon 330 with hot foil, flood and spot varnish, cold foil, two semi-rotary die cut stations (for changing dies during printing), slitting and dual rewind.

Although the Labelsprint press configuration was seen at Labelexpo Americas last year, there are big changes to the X-800 front end to facilitate full variable data capabilities as well as control of print parameters such as density and register. The X-800 now generates barcodes in a wide range of formats, on the fly during printing. During the show Xeikon printed 16,000 running meters (330 width) and generated more than 1million 1D, 2D and combination barcodes.

Xeikon also showed the first samples of a UV-curable toner on a PS label. This technology, first announced at Drupa, provides digitally printed labels with chemical resistance against solvent and heat exposure. The company was also demonstrating how the fifth print station on the 330 press can be used for security colors and spot colors, as well as for white.

Matan showed its SpringPro Tag digital press, together with two digital finishing solutions for label applications: the Allan Datagraph DFS Digital Finishing System and the ComPack DigiBeam Laser Die Cutting System. The SpringPro offers a resolution up to 400x1600dpi, with the ability to handle variable data including bar-coding and a choice of four, five, or six-color, one-pass printing, including a variety of popular spot colors, opaque white and metallic colors. The system was also featured on the stand of Grafische Systeme.

Domino has made the interesting transition from high speed inkjet coding and print&apply systems to the labels market, and used Labelexpo to launch its K-series drop-on-demand VIP print heads, built onto an ABG Omega SR330 rewinder. Each head is 61mm wide, and they can be stitched together to cover different web widths. The heads could be used either in-line on a flexo press, or as this kind of stand-alone solution, for example printing variable data from barcodes in pharmaceutical applications.

The K-series heads are designed to move beyond ‘part personalization’ applications to printing of complete documents. The K-200 prints at up to 90 meters/minute at resolutions up to 300dpi. Spot color printing will be offered along with Domino’s CMYK UV inks.

GRE’s Digital Solutions division announced it had signed an agreement with Impika, a French manufacturer of high-resolution drop-on-demand UV inkjet modules for labels, mailers and document processing. Its IPS C-9000, for example, prints at up to 900dpi at up to 24 m/minute. GRE plans to develop new types of high-end digital color printing lines using VIPcolor and/or Impika modules, incorporating such ancillaries as Longford RFID insetters and laser cutters from Cartes Equipment.

Primera Technology introduced its LX800 digital press to Europe, printing full-color labels and tags onto media as small as 1.5” (38mm) wide and .75” (19mm) long, up to a maximum of 8.25” (210mm) wide and 24” (610mm) long.  Print resolution is 4800x1200dpi. Targeted applications include primary product labels, box-end labels with photos or graphics, and a wide variety of other retail, office or industrial labels that can benefit from the use of on-demand, high-quality color printing. Substrates can include matte-finish labels as well as semi-gloss and high-gloss materials.

Nipson showcased its 1865 compact printer at the show, which is ideal for proofing and short production runs. Nipson’s digital production range also has the high-volume VaryPress 200 and 400, which are ideal for integrating with existing conventional presses. The Varypress 400 can reach speeds of 415 ft/min and can be integrated into a flexo or finishing configuration. Nipson presses feature a non-heat flash toner fusing, which enables printing on practically any substrate, from films and foils to tag stock. Minimal contact with the substrate means that the technology is ideal for adding variable data to RFID tags. All of Nipson’s printers achieve 600dpi quality and are compatible with 2D barcodes. 

Roger Pellow, Labelexpo managing director, said: ‘Digital technology is at the forefront of developments in the labels industry. There was a huge interest in the digital technology on display at Labelexpo Europe, and of course there will also be the all the latest digital printing solutions for labels on show at Labelexpo Asia in December. It’s going to be a great show.’